Modular last

ABSTRACT

A modular last system comprising: a frame and plurality of last segments removably attached to the frame, wherein the plurality of last segments each have an outer surface that defines an anatomical shape.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application is a non-provisional of and claims the benefit of U.S. provisional application No. 62/744,262, filed Oct. 11, 2018, which is hereby incorporated by reference in its entirety.

FIELD OF THE DISCLOSURE

The present application relates to a modular last to manufacture an article of clothing. More particularly, the present application relates to a modular last having a frame and at least one last segment removably supported on the frame, where the last segment defines a contour for the article of clothing.

BRIEF DESCRIPTION OF THE FIGURES

FIG. 1 is a perspective view of a modular last system according to an example.

FIG. 1A is an enlarged view of the area indicated in FIG. 1.

FIG. 2 is a perspective view of modular last system showing details of a frame according to an example.

FIG. 3 is a side view of a modular last system according to an example.

FIG. 4 is a top view of a modular last system according to an example.

FIG. 4A is a sectioned side view as might be seen along line 4A-4A in FIG. 4 showing further details of a modular last system according to an example with material applied to the last to form an article.

FIG. 5 is a side view schematically showing a modular last system having interchangeable last sections according to an example.

FIG. 6 is a side view schematically showing a modular last system having interchangeable last sections according to an example.

FIG. 7 is a side view schematically showing a modular last system having interchangeable last sections according to an example.

FIG. 8 is a top view schematically showing a modular last system having interchangeable last sections according to an example.

In the drawings, which are not necessarily drawn to scale, like numerals may describe similar components in different views. Like numerals having different letter suffixes may represent different instances of similar components. The drawings illustrate generally, and not by way of limitation, various examples discussed in the present document.

SUMMARY

Examples of the disclosure generally relate to a modular last comprising a frame; plurality of last segments removably attached to the frame, wherein the plurality of last segments each have an outer surface that defines an anatomical shape.

Another example relates to a modular last comprising a frame including an elongate member having a cross section; plurality of segments arranged on the frame to define an anatomical shape, the plurality of segments defining a channel configured to receive the elongate member therein.

DETAILED DESCRIPTION

Examples of the disclosure generally relate to a modular last for an article of clothing. The examples described herein will discuss the modular last in the context of manufacturing footwear including but not limited to shoes, boots, slippers, and the like. It will be understood that the modular last may be used to form other articles of clothing manufactured by forming a shape over a last including but not limited to a glove or hat.

The last determines the shape of the article of clothing and the cavity defined by the article. For footwear, the last is the starting point for determining the fit, performance, ergonomics and style of the shoe. The contour of the last is used to define the shape of the shoe for aesthetical and performance purposes. A designer designs a last for a particular article, and once the design is confirmed, the pattern of the last is graded to make different sizes. Existing lasts are formed from carved wood, cast aluminum or injection molded plastic. Last making is often considered an art form with skilled last makers having specialized education in last making. The last maker must consider every aspect of the anatomy for the article to be formed, and how the anatomy changes as the wearer moves.

Lasts are constructed as solid form requiring a separate last for each design. To produce the design in different sizes multiplies the number of lasts that are produced. As a result, large amounts of space are dedicated to storing lasts for each design in all of its various sizes. The unique nature of each last also makes it prohibitive to change the design after the last has been graded for different sizes. Design variation and modification is, therefore, discouraged by the nature of the last and limits the ability to customize or change the performance around a common last. As a result, there is a need for a last system that can be more easily modified and reduce the amount of shelf to store lasts of various sizes. In view of at least these needs, the disclosure provides a modular last system that generally includes a frame on which last segments are supported. As described more completely below, the modular last system may be used to interchange last segments to quickly modify the shape of the last without carving or molding an entirely new last as is currently practiced. In addition, the use of a frame to support last segments allows the segments to be removed from the frame for more compact storage. Further benefits of the modular last system will become apparent from the description below.

Footwear is often purpose built for various activities and environments. The ability to quickly modify a last or a portion of a last to tailor an existing footwear design for a particular activity or environment is desirable. Moreover, human anatomy varies to a great extent such that custom fitting or greater flexibility in fitting footwear is highly desirable. In footwear, the last includes a number of portions to help shape the footwear to a person's anatomy. With reference to FIGS. 3 and 4, considering the length or longitudinal components of the last from back to front, the last includes a heel H, ankle A, waist W and toe T portions. From the side, the last may include a forepart F and back part B, which may further include an instep I, a cone C, a heel curve HC, a counter point CP, and a top line point TP. A vamp point V may be formed where the cone joins the toe.

Last measurements include stick length SL measured from the longest points at the toe T and heel H. Ball girth BG is measured around the ball of the last. Instep girth IG is measured over the instep of the last. Last waist girth is measured around the waist of the last. Toe spring TS is the elevation of the toe T above a ground plane GP. The ground plane GP may be defined by the lower surface 102 of last system 100. Heel lift HL refers to the measurement from the ground plane GP to the heel curve. Long heel girth HG_(L) is measured around the last 100 from the lower surface 102 of the last 100 at the heel H to the upper surface 104 of last 100 at cone C. Short heel girth HGs is measured around the last 100 from the lower surface 102 of the last 100 at the heel H to the point where instep girth IG is measured. Width measurement across the bottom of the last include a ball width BW, instep width IW, waist width WW, and heel width HW measured at each respective section of the last.

With reference to FIG. 1 a modular last system is generally indicated by the number 100. Last system 100 generally includes a frame 110 and at least one last segment 120 that defines an anatomical shape 125. In the example plural last segments 120 are provided as discussed more completely below. Frame 110 may have any shape or size suitable for supporting last segments 120. As shown, frame 110 may be incorporated within last segments 120 to complete or form part of the shape 125. As best shown in FIG. 3, to form an article 10, material 12, which may be a natural or synthetic material including but not limited to various woven and non-woven textiles, rubber, polymeric material, leather, or fiber material, is attached to or wrapped around the last system 100 to form the article 10. In the example, the last system 100 defines an anatomical shape 125 that is a foot shape for forming a footwear article such as a shoe or boot 15.

With reference to FIG. 2, one example of frame 110 is shown in more detail. Frame 110 may include an elongate member 111 having a cross section 112. In the example, cross section 112 is a generally rectangular cross section, and frame 110 includes a top wall 113, a bottom wall 114 and opposing sidewalls 115, 116. As shown, frame 110 may be formed as a single piece. In other examples, multiple members may be joined or attached together to form frame 110. The cross section 112 of frame 110 may vary along its length in certain examples. In the depicted example, frame 110 has a constant cross section 112 along its length. Frame 110 may be formed of any material suitable for supporting the last segments 120 thereon including but not limited to metal, plastic, wood, ceramic, and combinations thereof. The material may be rigid or malleable. In the example, a metal material is used, such as a stainless steel or aluminum material. Frame 110 may extend along the entire stick length SL of last system 100 as shown or a portion thereof. To that end, frame 110 may have heel, ankle, waist and toe portions as shown generally in FIG. 3. The rear surface 117 of frame 110 may be curved to correspond to the heel curve HC and provide an uninterrupted surface when frame 110 is incorporated within last segments 120 as shown and described more completely below. Likewise, the front surface 118 of frame 110 may substantially conform to the shape of a toe segment. Toe end 119 of frame 110 may also extend upward to define toe spring TS.

The last segment 120 is supported on frame 110. In the example, last segment 120 is removably attached to the frame 110 to facilitate interchanging of segments to alter the profile of a particular segment or the overall anatomical shape 125. It will be understood that segment 120 may be removably attached to frame 110 by a fastener, clip, temporary adhesive, interference fit, dovetail connection, and the like. In the example, segment 120 defines a channel 130 that receives at least a portion of frame 110 therein. As discussed previously, channel 130 may have a cross-section 132 similar to cross section 112 of frame 110 to incorporate frame 110 within last segments 120. For example, channel 130 may have rectangular cross section, with a top surface 133 and side surfaces 135,136 that closely conform to the walls 113,115,116 of frame 110 to wholly receive frame 110 within channel 130. The side surfaces 135,136 of channel 130 may create an interference fit with the inserted portion of frame 110 to hold segments 120 in place once attached to frame 110.

As discussed, a plurality of last segments 120 may be used to form an anatomical shape 125 or other form to help shape an article 10. In the example, plural segments 120 are used to define a foot-like anatomical shape 125. Segments 120 may include a heel segment 121, toe segment 122, ankle segment 123 and waist segment 124. The segments 120 combine to form a lower surface 126 (FIG. 3) of the last system 100. Segments 120 also combine to form an upper surface 127 of the last system 100 (FIG. 1).

Each last segment 120 may be molded, carved or otherwise formed to have the desired shape used to define the article 10. With reference to FIGS. 5-7, segments 120 may be interchanged on the frame to alter the performance, appearance, fit or other aspect of the article 10 or the last system 100 itself. Providing a system 100 where segments 120 may be interchanged on frame 110 facilitates such modification without the need to mold an entire new last. In this way a single last system 100 may be used to form multiple variations of an article.

With reference to FIG. 5, an example of a performance variation for a shoe is depicted. In the example, last system 100 includes plural segments 120 on frame 110 to form an anatomical shape 125 that resembles a foot shape for forming an article 10 such as a shoe, boot or the like. In the example, segments may generally include a heel segment 140, a toe segment 150, a waist segment 160 and an ankle segment 170. It will be understood that these segments are provided as examples and are not limiting. Fewer or greater segments 120 may be used. For example, a pair of segments may be used with a first segment encompassing the heel and ankle portions and a second segment encompassing the waist and toe portions etc. The greater number of segments provides greater opportunity for modifying the shape by interchanging individual segments having different outer shapes as discussed more completely below.

For example as shown in FIG. 5, plural segments 120 may include a first heel segment 141 and a first toe segment 151 for purposes of the example. The first heel segment 141 and first toe segment are shown in solid lines in the figure. A second heel segment 142 and second toe segment 152 are shown in broken line. As depicted, first heel segment 141 has a first rear profile 143. This segment may be interchanged with second heel segment 142 that has a second rear profile 144 that may provide a performance fit. For example, as shown, second profile 144 may be more fitted with a profile that conforms more closely to the anatomy of a foot. As shown, this may result in a smaller radius at heel cup HC and a larger radius forming the top part TP of second heel segment 142.

With continued reference to FIG. 5 and FIG. 6, a first toe segment 151 having a first toe shape 153 may be replaced by a second toe segment 152 having a second toe shape 154. In the example, first toe segment 151 defines a first toe shape with a rounded front surface 155 and tapered profile 157. The second toe segment 152 has a more square front surface 156 and a less tapered profile 158 to produce a more boxier toe shape. This example demonstrates how segments may be interchanged to change the look of the article 10. It will be understood that similar changes may also be used to change the performance or fit as well.

With reference to FIGS. 7 and 8, an example is provided showing a first waist segment 161 having a first cone profile 163 forming a first instep girth IG₁. A second waist segment 162 (broken lines) has a second cone profile 164 forming a second instep girth IG₂. In the example, second cone profile 164 extends outward in comparison to first cone profile 163 causing the second instep girth IG₂ to be greater than first instep girth IG₁.

EXAMPLES Example 1

A modular last system comprising: a frame; plural last segments removably attached to the frame, wherein the plural last segments each have an outer surface that defines an anatomical shape.

Example 2

The system of example 1, wherein the at least one last segment defines a channel, wherein at least a portion of the frame is received in the channel.

Example 3

The system of example 2, wherein the at least one last segment has an upper surface and a lower surface, wherein the channel is defined in the lower surface.

Example 4

The system of example 3, wherein the upper surface defines the anatomical shape.

Example 5

The system of example 4, wherein the anatomical shape is a foot.

Example 6

The system of example 1, wherein the plural last segments include a first heel segment defining a first heel profile, and a first toe segment defining a first toe profile

Example 7

The system of example 6 further comprising a second heel segment having a second heel profile, wherein the first heel segment and second heel segment are interchangeable on the frame to alter the anatomical shape.

Example 8

The system of example 7 further comprising a second toe segment having a second toe profile, wherein the first toe segment and second toe segment are interchangeable on the frame to alter the anatomical shape.

Example 9

The system of example 6, wherein the plural last segments further include an ankle segment.

Example 10

The system of example 6, wherein the plural last segments further include a first waist segment having a first girth and a second waist segment having a second girth, wherein the first waist segment and second waist segment are interchangeable to alter the anatomical shape.

Example 11

The system of example 1, wherein the frame includes an elongate member having a frame cross-section and a frame profile; the plural last segments defining a channel that conforms to the frame cross-section, wherein the plural last segments are removably attached to the frame by an interference fit between the frame and the channel.

Example 12

The system of example 11, wherein the channel is defined in a lower surface of the plural last segments, wherein upon attaching the plural segments to the frame, a lower surface of the frame is contiguous with the lower surface of the plural segments.

Example 13

The system of example 11, wherein the cross section of the frame is rectangular.

Example 14

The system of example 1, wherein the frame includes a heel portion and a toe portion spaced longitudinally from each other by a waist portion, wherein a lower surface of the waist portion defines a base plane, and wherein the toe portion of the frame extends upward relative to the base plane.

Example 15

The system of example 1, wherein the frame is constructed of a unitary member.

Example 16

A modular last system comprising: a frame including an elongate member having a cross section; plural segments arranged on the frame to define an anatomical shape, the plural segments defining a channel configured to receive the elongate member therein.

Example 17

The system of example 16, wherein the anatomical shape is a foot.

Example 18

The system of example 16, wherein the cross section of the elongate member is rectangular having a top wall, a bottom wall, and opposing sidewalls, and wherein the channel includes side surfaces that are spaced from each to form an interference fit with the opposing sidewalls of the elongate member.

Example 19

The system of example 16, wherein the plural segments include a first segment forming a portion of the anatomical shape having a first profile, wherein the system further comprises a second segment interchangeable with the first segment to form the portion of the anatomical shape with a second profile.

Example 20

The system of example 19, wherein the second profile extends inward relative to the first profile.

Example 21

The system of example 1 further comprising a material attached to the plural last segments to define an article.

Example 22

The system of example 16 further comprising a material attached to the plural last segments to define an article. 

1. A modular last system comprising: a frame; and a plurality of last segments removably attached to the frame, wherein each last segment the plurality of last segments has an outer surface that defines an anatomical shape.
 2. The system of claim 1, wherein at least one last segment of the plurality of the last segments defines a channel, wherein at least a portion of the frame is received in the channel.
 3. The system of claim 2, wherein at least one last segment of the plurality of the last segments has an upper surface and a lower surface, wherein the channel is defined in the lower surface.
 4. The system of claim 3, wherein the upper surface defines the anatomical shape.
 5. The system of claim 4, wherein the anatomical shape is a foot.
 6. The system of claim 1, wherein the plurality of last segments comprises a first heel segment defining a first heel profile, and a first toe segment defining a first toe profile.
 7. The system of claim 6, further comprising a second heel segment having a second heel profile, wherein the first heel segment and second heel segment are interchangeable on the frame to alter the anatomical shape.
 8. The system of claim 6, further comprising a second toe segment having a second toe profile, wherein the first toe segment and second toe segment are interchangeable on the frame to alter the anatomical shape.
 9. The system of claim 6, wherein the plurality of last segments further comprise an ankle segment.
 10. The system of claim 6, wherein the plurality of last segments further comprise a first waist segment having a first girth and a second waist segment having a second girth, wherein the first waist segment and second waist segment are interchangeable to alter the anatomical shape.
 11. The system of claim 1 further comprising a material disposed adjacent at least a portion of the plurality of last segments to define an article.
 12. The system of claim 1, wherein the frame comprises an elongate member having a frame cross-section and a frame profile; and the plurality of last segments defining a channel that conforms to the frame cross-section, wherein the plurality of last segments are removably attached to the frame by an interference fit between the frame and the channel.
 13. The system of claim 12, wherein the channel is defined in a lower surface of the plurality of last segments, wherein upon attaching the plurality of segments to the frame, a lower surface of the frame is contiguous with the lower surface of the plurality of segments.
 14. The system of claim 12, wherein the cross section of the frame is rectangular.
 15. The system of claim 1, wherein the frame comprises a heel portion and a toe portion spaced longitudinally from each other by a waist portion, wherein a lower surface of the waist portion defines a base plane, and wherein the toe portion of the frame extends upward relative to the base plane.
 16. The system of claim 1, wherein the frame is constructed of a unitary member.
 17. A modular last system comprising: a frame including an elongate member having a cross section; and a plurality of segments arranged on the frame to define an anatomical shape, the plurality of segments defining a channel configured to receive the elongate member therein.
 18. The system of claim 17, wherein the anatomical shape is a foot.
 19. The system of claim 17, wherein the cross section of the elongate member is rectangular having a top wall, a bottom wall, and opposing sidewalls, and wherein the channel comprises side surfaces that are spaced from each to form an interference fit with the opposing sidewalls of the elongate member.
 20. The system of claim 17 wherein the plurality of segments comprise a first segment forming a portion of the anatomical shape having a first profile, wherein the system further comprises a second segment interchangeable with the first segment to form the portion of the anatomical shape with a second profile. 